Durable fiber optic diffuser tip and method of making same

ABSTRACT

A method of manufacturing a medical instrument for diffusing light from an optical fiber is provided. The medical instrument includes an optical fiber having a proximal portion including a cladding layer surrounding the core and a distal portion having a diffuser tip comprising a protective coating made of acrylic or methylpentene surrounding the core, an optical coupling layer, and a sleeve. The protective coating strengthens the distal end of the optical fiber so that it can withstand a higher bending moment at failure than the uncladded core. At the same time, the protective layer has an index of refraction that is between the indices of refraction of the core and the optical coupling layer to direct light out of the core through to the optical coupling layer.

This divisional patent application claims priority to pending U.S.patent application Ser. No. 09/532,893, “Durable Fiber Optic DiffuserTip and Method of Making Same” filed Mar. 22, 2000 now U.S. Pat. No.5,361,530 B1.

FIELD OF THE INVENTION

The present invention relates, in general, to an improved, more durablediffuser tip to diffuse light from a light-emitting end of an opticalfiber. More particularly, the invention relates to a diffuser whichincludes a decladded optical fiber core which is covered by a protectivecoating and an optical coupling layer wherein the protective coating hasan index of refraction between the indices of refraction of the core andthe optical coupling layer while at the same time the protective coatingincreases the bending moment required to break the core. The protectivecoating is made of polymethyl methacrylate or methylpentene.

BACKGROUND OF THE INVENTION

Surgeons commonly use lasers to treat benign prostatic hyperplasia, orBPH. BPH is a condition of an enlarged prostate gland. The prostategland with BPH typically increases in size to between about two and fourtimes normal. The lasers used to treat it must have durable diffusertips that distribute light radially in a predictable manner and bendwithout breaking. Small diffuser tips offer an advantage to the surgeonas well. Builders of these diffuser tips commonly make them from opticalfibers and desire to make them small.

An optical fiber typically contains a glass core surrounded by claddingand a jacket. The cladding protects the inherently weaker glass core bylending mechanical support to the core. The cladding also has an indexof refraction lower than that of the core to block light from emergingradially from the core.

A prior art diffuser tip based on art taught by Esch in U.S. Pat. No.5,754,717 is shown in FIG. 1. This figure shows a prior art diffuser tipcomprised of the stripped core of a typical optical fiber, an opticalcoupling layer, and a sleeve. The optical coupling layer, replacing thecladding of the optical fiber, has an index of refraction exceeding thatof the core to pull the light out of the core using well known physicalprinciples. The sleeve, which surrounds the optical coupling layer, hasan index of refraction lower than the optical coupling layer andincludes barium sulfate particles to help scatter the light. In order toallow light to pass through the boundary between the optical couplinglayer and the sleeve, the inner diameter of the sleeve is abraded.Abrading the surface of the sleeve presents surfaces more nearly normalto the light coming through the optical coupling layer so that the lightpasses into the sleeve. By controlling the extent of the abrasions, thelight intensity as a function of the position along the axis of thesleeve can also be controlled. Designers often prefer an evendistribution of light for applications involving BPH.

A diffuser tip taught by Khoury in U.S. Pat. No. 5,151,096 comprises alayer of medical grade epoxy over the core. Medical grade epoxy has anindex of refraction higher than that of silicone and so cannot be usedin an application having a silicone optical coupling layer.

The process of making the diffuser tip illustrated in FIG. 1 involvesstripping a portion of the optical fiber cladding layer away from theoptical fiber core. The sleeve is then filled with an appropriatematerial such as silicone and the declad portion of the core is insertedinto the sleeve. Since the cladding layer provides structural supportfor the core, stripping it away makes the declad portion of the opticalfiber core more susceptible to cracking or breaking when it is bent. Theproblem of cracking or breaking becomes more acute as the diameter ofthe optical fiber core becomes smaller. While the optical coupling layerand sleeve protect the declad portion of the optical fiber core, thesupport provided is not as great as the support provided by the claddinglayer. It would, therefore, be advantageous to design a diffuser tipwherein the resistance of the declad core to cracking or breaking isimproved. It would further be advantageous to design a more resilientdiffuser tip without substantially changing the light emittingproperties of current designs.

SUMMARY OF THE INVENTION

One embodiment of the present invention includes a diffuser tipfashioned from an optical cable's stripped glass core surrounded by adurable protective coating of acrylic and an optical coupling layer. ATeflon sleeve impregnated with barium sulfate covers the opticalcoupling layer. The optical coupling layer transfers the light from theprotective coating through to the sleeve. The index of refraction of theprotective coating exceeds that of the core to couple light from thecore by well-known physical principles. The index of refraction of theoptical coupling layer exceeds that of the protective coating to couplethe light from the protective coating to the sleeve. The material of theprotective coating, by enhancing the strength of the declad core whileeffectively coupling light out of the core to the optical couplinglayer, results in an operative diffuser tip that increases the bendingmoment at which the declad core breaks. In a particular embodiment ofthe invention the coating comprises polymethyl methacrylate. In afurther embodiment of the invention the coating comprises methylpentene.

In a further embodiment of the invention the inner surface of the sleeveis abraded to couple light from the optical coupling layer into thesleeve. The sleeve's index of refraction is lower than the index ofrefraction of the optical coupling layer. The abrasion scatters thelight rays to allow them to pass into the sleeve when the light raystravel from a layer of higher refractive index to a layer of lowerrefractive index.

BRIEF DESCRIPTION OF THE DRAWINGS

The novel features of the invention are set forth with particularity inthe appended claims. The invention itself, however, both as toorganization and methods of operation, together with further objects andadvantages thereof, may best be understood by reference to the followingdescription, taken in conjunction with the accompanying drawings inwhich:

FIG. 1 is a section view of a prior art diffuser tip.

FIG. 2 is a diagram view of a laser device utilizing the diffuser tipassembly according to the present invention.

FIG. 3 is a section view of an embodiment of the diffuser tip assemblyaccording to the present invention showing, from inside to the surface,a core, a protective coating, an optical coupling layer, and a sleeve.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 2 illustrates schematically a medical instrument 20 for diffusinglight from an optical fiber. The medical instrument 20 includes a sourceof light energy 22, preferably a laser. An optical fiber 28 connects tothe source of light energy 22 through a connection port 24 through tothe diffuser tip 14. The diffuser tip 14 is affixed at the distalportion 31 of the optical fiber 28 creating the diffuser tip assembly34. FIG. 3 shows that proximal to the diffuser tip 14, a core 10radially surrounded by cladding 32 and a jacket 38 forms the proximalportion 30 of the standard optical fiber 28. The optical fiber 28 mayalso have a buffer layer 42 placed circumferentially between thecladding 32 and the jacket 38. The material used to create the cladding32 has an index of refraction lower than the index of refraction of thematerial used to create the core 10.

FIG. 3 is a section view of one embodiment of the diffuser tip assembly34 according to the present invention. In the embodiment illustrated inFIG. 3, a protective coating 12 surrounds the unclad core 10 at thedistal portion 31 of the optical fiber 28. A material having an index ofrefraction between the indices of refraction of the core 10 and theoptical coupling layer 40 forms the protective coating 12. Polymethylmethacrylate, commonly called acrylic, can be used to form theprotective coating 12 when the core 10 is made from silica glass. In afurther embodiment, methylpentene can be used to form the protectivecoating 12 when the core is made from silica glass. Silica glass has anindex of refraction of 1.45 and polymethyl methacrylate has an index ofrefraction of 1.488. TPX™ brand of methylpentene, available from MitsuiPetrochemical Industries, Ltd. in Tokyo, Japan, has an index ofrefraction of 1.463. An optical coupling layer 40 surrounds theprotective coating 12. General Electric XE5844 Silicone, having an indexof refraction of 1.51, can be used to form the optical coupling layer40. Proximal of the distal end of diffuser tip 14, the protectivecoating 12 surrounds the portion of the core 10 that has cladding 32remaining on it but has had the jacket 38 removed.

In the embodiment of the invention, the material properties used in theprotective coating 12 cause the desirable qualities. The material usedin the protective coating 12 has an index of refraction between that ofthe core 10 and the optical coupling layer 40. The protective coating 12also increases the ability of the optical fiber to withstand bendingwithout breaking.

The sleeve 16 surrounds the optical coupling layer 12. The sleeve 16 maybe comprised of perfluoroalkoxy containing 10% barium sulfate and has anindex of refraction lower than the index of refraction of the opticalcoupling layer 40. Because the index of refraction decreases across theinterface 36 of the optical coupling layer 40 and sleeve 16 as lightmoves from the optical coupling layer 40 to the sleeve 16, the interface36 between the sleeve 16 and the optical coupling layer 40 is roughened,or abraded, to allow light to diffuse through the interface 36. Thisabrasion can take place on the inner surface of the sleeve 16. Theabrasion can vary along the axial length of the diffuser tip 14. Varyingthe roughness allows the diffuser tip 14 to distribute light in a manneradvantageous for the application.

A slug 18 can be placed at the end of core 10 to reflect light. The slug18 can be comprised of alexandrite particles mixed into UV-10 Medicaladhesive and cured in place. The same outer dimension as the core 10 ora smaller dimension can serve as the outer boundary of the slug 18.UV-10 Medical adhesive is available from Master Bond, Inc., Hackensack,N.J.

FIGS. 2 and 3 illustrate components that direct the light. Light travelsfrom the source of light energy 22 through the connection port 24 andout through the core 10 of the optical fiber 28. The light proceedsthrough the core 10 of the optical fiber 28 without leaking through thecladding 32 because of the lower index of refraction in the cladding 32.The light then moves to the portion of the core 10 in the interior ofthe diffuser tip 14. Light emerges from the optical fiber 28 to thediffuser tip 14 where the protective coating 12 has an index ofrefraction higher than the index of refraction of the core 10. Thehigher index of refraction of the protective coating 12 pulls the lightout of the core 10. The light then moves to the optical coupling layer40, through the interface 44 between the optical coupling layer 40 andthe protective coating 12, pulled from the protective layer 12 by thehigher index of refraction of the optical coupling layer 40.

A lower index of refraction in the sleeve 16 than in the opticalcoupling layer 40 necessitates a roughened surface between them. Theroughened, or abraded, nature of the inner surface of the sleeve 16presents small surface portions that alter the normal trajectory of thelight rays. Light rays, now altered in direction, approach the sleeve 16at a more nearly normal angle allowing them to escape. Varying theroughness along the axial length of the abraded surface varies theintensity of the light as a function of the axial distance along thediffuser tip 14.

An alexandrite filled slug 18 placed distally to the core 10 causeslight reaching the end of the core to scatter back through the core 10.Backscatter of light at the distal end of the diffuser tip 14 raises theintensity of the light nearer the distal end of the diffuser tip 14.

Scattering materials other than alexandrite can fill the slug 18, forexample, aluminum oxide, titanium dioxide, or diamond powder.Alexandrite, however, fluoresces in a temperature-dependent mannerdetectable in ways known in the art.

Performing a simple experiment compares the bending moments tolerated bya bare core 10 and the core 10 coated with the protective coating 12.Test the moments using a section of bare core 10 and another section ofcore 10 with only the protective coating 12 retained on it. Strip thejacket 38, the buffer layer 42, and the cladding 32 from a length ofoptical fiber 28. Restrain the created length of bare core 10 in a testfixture. Place a measured force perpendicular to the axis of the barecore 10 at a known distance from the restraint point. Increase the forceuntil the bare core 10 breaks. Multiply the force at which the core 10breaks by the distance from the restraint point to obtain the bendingmoment at failure. Repeat this test for a length of core 10 coated withonly protective coating 12. The proper protective coating 12 raises thebending moment at failure of the core 10. A more durable diffuser tipresults.

A diffuser tip 14 can be created by using this process. Strip the jacket38 and the cladding 32 from the optical fiber 28. Leave the bare core 10covered with the cladding 32 exposed for a distance and the bare core 10itself exposed for a distance further. Dip the exposed portions a numberof times into a substance such as an acrylic monomer solution until thethickness of the protective coating 12 reaches the desired level. Theacrylic monomer solution can be, for example, 35% by weight of acrylicmonomer dissolved in 65% by weight of methylene trichloroethylene. Allowthe acrylic to dry. Close a piece of the sleeve material at one end,fill the created sleeve 16 with the liquid material for the opticalcoupling layer, then slide the sleeve 16 onto the hardened acrylicpolymer. Heat stake into position. Using a hot mold closes the sleeve 16and may, if desired, produce a pointed tip 42. The inner surface of thesleeve 16 may be roughened with a tool, for example, a small brush.

The technician can alternatively place the molded slug 18 into thesleeve before assembling it to the coated core. To add the molded slug18, place the molded slug 18 filled with a light scattering materialinto the sleeve 16. Follow by placing the sleeve 16 over the protectivecoating 12. A material such as silicone may form the slug 16.

The optical coupling layer 40, in addition to coupling light from theprotective layer 12, helps hold the sleeve to the protective coating 12.The adhesive properties of the optical coupling layer 40 help whencoiling the optical fiber 28. The coiling pulls the core 10 of theoptical fiber 28 through the jacket 38 causing a relative motion betweenthe core 10 and the jacket 38 known as “pistoning.” The adhesiveproperties prevent pistoning and keep the core 10 and its protectivecoating 12 in the sleeve.

It will be recognized that equivalent structures may be substituted forthe structures illustrated and described herein and that the describedembodiment of the invention is not the only structure which may beemployed to implement the claimed invention. For example, the pattern ofroughening may distribute the light in an uneven manner advantageous tothe application.

While preferred embodiments of the present invention have been shown anddescribed herein, it will be obvious to those skilled in the art thatsuch embodiments are provided by way of example only. Numerousvariations, changes, and substitutions will now occur to those skilledin the art without departing from the invention. Accordingly, it isintended that the invention be limited only by the spirit and scope ofthe appended claims.

What is claimed is:
 1. A method of manufacturing a medical instrumentincluding a durable diffuser tip, said method comprising the steps of:selecting an optical fiber comprising a cladding and a core wherein saidcore has a first bending moment at failure; stripping said cladding fromsaid optical fiber leaving said core exposed for a distance; selecting acoating substance that cares into a polymethyl methacrylate coatinghaving an index of refraction higher than said core and wherein saidcore including said polymethyl methacrylate coating has a bending momentat failure higher than said first bending moment at failure, dippingsaid core at least once into said coating substance; selecting a liquidthat cures into an optical fiber coupling layer having an index ofrefraction higher than said polymethacrylate coating; filling a sleevewith said liquid; sliding said sleeve over the coated core; and stakingsaid sleeve into place.
 2. The method of claim 1 wherein said opticalcoupling layer comprises silicone.
 3. The method of claim 1 wherein saidsleeve comprises an inner surface, and said method further comprises thestep of roughening said inner surface of said sleeve.
 4. The method ofclaim 1 further comprising placing a slug containing alexandriteparticles into said sleeve.
 5. A method of manufacturing a medicalinstrument including a durable diffuser tip, said method comprising thesteps of: selecting an optical fiber comprising a cladding and a corewherein said core has a first bending moment at failure; stripping saidcladding from said optical fiber leaving said core exposed for adistance; selecting a coating substance that cures into a methylpentenecoating having an index of refraction higher than said core and whereinsaid core including said coating has a bending moment at failure higherthan said first bending moment at failure; dipping said core at leastonce into said coating substance; selecting a liquid that cures into anoptical fiber coupling layer having an index of refraction higher thansaid methylpentene coating; filling a sleeve with said liquid; slidingsaid sleeve over the coated core; and staking said sleeve into place. 6.The method of claim 5 wherein said optical coupling layer comprisessilicone.
 7. The method of claim 5 wherein said sleeve comprises aninner surface, and said method further comprises the step of rougheningsaid inner surface of said sleeve.
 8. The method of claim 5 furthercomprising placing a slug containing alexandrite particles into saidsleeve.